“ZCS-QGM2040CHigh pressure common rail needle valve body three grinding head ultrasonic gas static pressure high-precision internal cylindrical grinder”Using air static pressure ultrasonic workpiece electric spindle, 3 sets of ultrasonic air static pressure grinding wheel electric spindle (2 inner circular shafts and 1 end face shaft), and dedicated CBN grinding wheel dressingHydrostatic electric spindleNatural granite bed frame, The X/Z axis adopts ultra precision air floating guide rails, Spanish Fagor high-precision grating rulers, driven by high-precision linear motors, AE air clearance sensors, Renishaw online measurement, robot loading and unloading, and Siemens 828D high-precision CNC system. Achieve a machining accuracy of 0.3um roundness, 1um cylindricity, and Ra0.05um smoothness for the entire machine. The specific technical parameters are as follows:

1、 Technical features:

This machine tool is suitable for high-pressure common rail fuel injector componentsGrinding and grinding of the inner cone, middle hole, and seat surface of the needle valve body.

The grinder adoptsultrasonicPneumatic pressure workpiece electric spindle,ultrasonicPneumatic pressure grinding wheel electric spindle, pneumatic pressure grinding wheel dressing electric spindle,X/Z-axis ultra precisionAir floating guide rail,All adopted“Nano carbon fiber materials”The high rigidity, large load-bearing capacity, low air consumption, self-lubricating, and wear-resistant high-precision air static pressure spindle and air static pressure guide rail produced have the characteristics of low-carbon and green environmental protection.

The whole machine adoptsSiemens828D high-precision CNC system, realizing two line and five rotation spindle control.Make the whole machine achieve roundness0.3um, cylindricity 1um、SmoothnessRa0.05um machining accuracy.

The ultrasonic gas static pressure workpiece electric spindle adopts a permanent magnet synchronous motor, built-in encoder, and synchronous driver to achieve stepless speed regulation. The spindle is equipped with a precision diaphragm air pressure quick clamp, which is waterproof and dustproof, and has a repeated clamping accuracy of ≤ 2umIt can achieve automatic card loading function of the robotic arm. The workpiece spindle has a central cooling hole, and the coolant enters the front end from the rear of the spindle and sprays out, resulting in excellent cooling effect.

● Inner circleThe grinding wheel electric spindle adopts ultrasonic gas static pressure electric spindle with rated speed120000 revolutions per minute, driven by a frequency converter to achieve stepless speed regulation.

●The ultrasonic mechanism is built into the spindle,ultrasonicStop and Start、Frequency and amplitudeControl changesJust adjust the spindleofThe intake pressure can be achieved.Ultrasonic vibration processing,haveStrong grinding force and small cutting amount,Processing efficiencyhighImproveProcessing accuracy andSurface smoothness, extended service life of grinding wheel, and low adhesion of grinding wheel.

CBN grinding wheel dressing can be done in two ways: one is using a 12000 rpm, 55mm diameter grinding wheel dressing air static pressure electric spindle, installed on a rotatable precision servo slide table for dressing conical CBN grinding wheels; The second is a 70mm diameter dressing grinding wheel installed at the front end of the workpiece shaft head for dressing the inner circle and end face CBN grinding wheel of the middle hole.

●X/ZThe shaft adopts ultra precision technologyAir floating guide rail，Spanish LigueHigh precision grating ruler, driven by a high-precision linear motor.

● Robot dual claw typeThe loading and unloading device of the robotic arm grabs the workpiece to be processed from the material tray and sends it to the lower part of the workpiece axis fixture mouth. At this time, the second claw aligns with the fixture mouth to grab and remove the processed workpiece, and then flips it to feed the workpiece into the fixture. The robotic arm returns and sends the processed workpiece to the material tray.

The workpiece cooling adopts oil cooling method, and the oil filtration adopts precision oil filtration system with a filtration accuracy of less than 1um.

● Equipped with independent compressed air freeze dryer, independent electric spindle linear motor chiller, independent oil coolant chiller, and independent screw air compressor.

Equipped with a Renishaw online precision measuring instrument from the UK, with a measurement accuracy of 1um, used for measuring the machining dimensions of workpieces and achieving automatic control of dimensional tolerances.

● Two sets of AE sensors (optional), one set of non-contact AE sensor is built into the dressing wheel electric spindle, used for grinding wheel dressing, air clearance, and collision prevention; A set of fluid AE sensors is installed at the front end of the workpiece shaft, used for reducing backlash and preventing collisions during workpiece grinding.

The machine tool bed is made of high-quality natural graniteHas organizational stability and a solid structure. Fully enclosed outer cover.

The grinder is equipped with pressure sensors at the inlet of the air and water circuits, which have fault alarm protection functions such as overcurrent, overload, air pressure below the lower limit, and cooling water cut-off. And it has communication function with the upper computer (RS-485).

2、 Main Technical Parameters Table of the Whole Machine

3、 Outline drawing of machine tool

4、 Installation requirements for use

1Operator requirements: This machine tool is a high-precision CNC grinder, and the operator is required to have basic skills in operating CNC grinders. They must receive training from Party B and master safety operating procedures before they can use it.

2Installation and environmental requirements:

Supply voltage fluctuation within ± 10%Within, the working temperature must be installed in a constant temperature room（20Used within ℃± 1 ℃The humidity is less than75%, installation should be away from the seismic source. If conditions permit, isolation trenches can be made. The horizontal placement of the equipment should be less than 0.02mm, and adjustable shims can be used to adjust the level.

3、The compressed air source requires three-stage filtration. This machine tool is equipped with a precision three-stage filter, but the supply air source needs to be processed by a dryer, requiring a pressure of0.5-0.7MPa range, moisture content less than 90%, oil content less than 90%, temperature 17-19 ℃, impurity content less than 1um.

4. The spindle cooling water requires constant temperature, with a temperature range of 17-19 ℃, a flow rate of 2L/min, and a pressure of 2-3kg.